Methods for processing a substrate using multiple substrate support positions

Abstract

In some embodiments, a method for processing a substrate in a process chamber having a substrate support configured to move in a direction perpendicular to a top surface of a cover ring of a process kit may include positioning the substrate support in a first position such that a top surface of the substrate is positioned about 3 mm above to about 10 mm below a top surface of a cover ring of a process kit disposed about the periphery of the substrate support; performing a plasma deposition process while the substrate support is in the first position; moving the substrate support to a second position such that the top surface of the substrate is disposed about 3 mm below to about 15 mm above the top surface of the cover ring; and performing a plasma etch process while the substrate support is in the second position.

The invention claimed is: 
     
       1. A method for processing a substrate in a process chamber having a substrate support configured to move in a direction perpendicular to a top surface of a cover ring, the method comprising:
 moving the substrate support to a first position such that a top surface of the substrate is positioned about 3 mm above to about 10 mm below the top surface of the cover ring disposed about a periphery of the substrate support; 
 performing a plasma deposition process within the process chamber while the substrate support is in the first position; 
 moving the substrate support to a second position such that the top surface of the substrate is disposed about 3 mm below to about 15 mm above the top surface of the cover ring, wherein the second position is different from the first position; and 
 performing a plasma etch process within the process chamber while the substrate support is in the second position, wherein a position of the cover ring is not changed between the plasma deposition process and the plasma etch process performed. 
 
     
     
       2. The method of  claim 1 , wherein positioning the substrate support in the first position comprises positioning the substrate support such that the top surface of the substrate is positioned beneath the top surface of the cover ring, and wherein positioning the substrate support in the second position comprises positioning the substrate support such that the top surface of the substrate is above the top surface of the cover ring. 
     
     
       3. The method of  claim 1 , wherein the substrate support is moved to the second position subsequent to performing the plasma deposition process. 
     
     
       4. The method of  claim 1 , wherein the etch process removes at least a portion of material deposited during the deposition process. 
     
     
       5. The method of  claim 1 , wherein the plasma deposition process is a physical vapor deposition process. 
     
     
       6. The method of  claim 1 , wherein the plasma deposition process and the plasma etch process are high frequency RF plasma processes utilizing a RF power source operating a frequency of about 13.56 to about 60 MHz. 
     
     
       7. A method for processing a substrate disposed on a substrate support in a process chamber, comprising:
 moving the substrate support to a first position such that a top surface of the substrate is positioned about 3 mm above to about 10 mm below a top surface of a cover ring disposed about a periphery of the substrate support; 
 performing a plasma deposition process within the process chamber while the substrate support is in the first position to deposit a material on the substrate; 
 subsequently moving the substrate support to a second position such that the top surface of the substrate is disposed about 3 mm below to about 15 mm above the top surface of the cover ring; and 
 performing a plasma etch process within the process chamber while the substrate support is in the second position, wherein the plasma etch process removes at least a portion of the material deposited during the plasma deposition process, and wherein a position of the cover ring is not changed between the plasma deposition process and the plasma etch process performed. 
 
     
     
       8. The method of  claim 7 , wherein positioning the substrate support in the first position comprises positioning the substrate support such that the top surface of the substrate is positioned beneath the top surface of the cover ring, and wherein positioning the substrate support in the second position comprises positioning the substrate support such that the top surface of the substrate is above the top surface of the cover ring. 
     
     
       9. The method of  claim 7 , wherein the plasma deposition process is a physical vapor deposition process. 
     
     
       10. The method of  claim 7 , wherein the plasma deposition process and the plasma etch process are high frequency RF plasma processes utilizing a RF power source operating a frequency of about 13.56 to about 60 MHz.